U.S. patent application number 11/559841 was filed with the patent office on 2008-08-07 for molded plastic panel.
Invention is credited to Claude Brown, Monty Cochran, David Jacobson, Wayne Moore, Corwyn Strout.
Application Number | 20080185745 11/559841 |
Document ID | / |
Family ID | 39675478 |
Filed Date | 2008-08-07 |
United States Patent
Application |
20080185745 |
Kind Code |
A1 |
Strout; Corwyn ; et
al. |
August 7, 2008 |
MOLDED PLASTIC PANEL
Abstract
A molded panel for buildings is manufactured in a manner that
permits the blocking tab along the upper edge of the panel to be
molded in a position that is close to its final desired position.
Pressure is applied to the locking tab as it cools, thereby
bringing the locking tab into its final position.
Inventors: |
Strout; Corwyn; (Lee's
Summit, MO) ; Brown; Claude; (Gibsonia, PA) ;
Jacobson; David; (Sewickley, PA) ; Moore; Wayne;
(Frankfurt, KY) ; Cochran; Monty; (Cumming,
GA) |
Correspondence
Address: |
LATHROP & GAGE LC
2345 GRAND AVENUE, SUITE 2800
KANSAS CITY
MO
64108
US
|
Family ID: |
39675478 |
Appl. No.: |
11/559841 |
Filed: |
November 14, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60738282 |
Nov 18, 2005 |
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Current U.S.
Class: |
264/35 |
Current CPC
Class: |
Y10T 428/24273 20150115;
E04F 13/0864 20130101 |
Class at
Publication: |
264/35 |
International
Class: |
E04B 1/16 20060101
E04B001/16 |
Claims
1. A method of producing a plastic panel for attachment to a
building surface, comprising: injecting plastic into a mould to
form a body in an injection moulding process comprising the
application of heat to form said body, said body including at least
one row having a pre-selected appearance and an attachment hem
adjacent an upper portion of said body, said attachment hem having
a locking tab projecting therefrom; removing said mould and
permitting said body to cool; and applying pressure to said locking
tab hem during cooling to permit said locking tab to solidify in a
desired position.
2. The panel formed by the method of claim 1 wherein said locking
tab is continuous.
3. The panel formed by the method of claim 1 wherein said at least
one row having a pre-selected appearance comprises an upper row of
simulated shingles and a lower row of simulated shingles below said
upper row.
4. The panel according to claim 2 wherein at least one of said
lower and said upper row of simulated shingles is irregularly
spaced.
5. The panel formed by the method of claim 1 wherein said body
further comprises at least one side flange extending laterally
outwardly of said body, said side flange defining a fastening slot
for inserting a fastener therethrough to attach said panel to a
building wall, wherein said slot extends at an acute angle of about
5-30.degree. relative to horizontal.
6. The panel formed by the method of claim 1 wherein said panel
comprises exterior wall siding.
7. The panel formed by the method of claim 1, wherein said panel
comprise a roofing panel.
Description
[0001] This application claims the benefit of the filing date of a
provisional application Ser. No. 60/738,282 which was filed on Nov.
18, 2005.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to molded plastic panels for
covering building surfaces.
[0004] 2. Description of the Related Art
[0005] Molded plastic siding panels for exterior building walls are
known in the prior art. These molded panels are made from synthetic
thermoplastic polymers, including polypropylene, polyethylene, and
various mixtures and copolymers thereof.
[0006] Laterally elongated molded plastic panels are nailed to a
wall support surface in horizontal rows partially overlapping each
other in order to provide a pleasing appearance combined with a
weather-resistant protective layer over the support surface.
[0007] The molded plastic panels are typically installed by
securing several adjacent courses to a wall support surface,
starting with a bottom course. A lower marginal edge region of each
panel in courses above the bottom course overlaps a panel in the
course immediately below. Side marginal edge regions of each panel
overlap side marginal regions of adjacent panels.
[0008] Various mechanisms have been proposed for interlocking lower
marginal edge regions of the plastic panels with panels in the
course immediately below. Some of these methods include a locking
tab extending forwardly and downwardly from the top of each panel,
and a return leg extending upwardly and rearwardly from the bottom
of each panel. As each panel is installed, the return leg of the
panel being installed is interlocked with the locking tab of the
panel below it, which has previously been installed. These
interlocking components may require difficult and time consuming
manufacturing processes.
[0009] U.S. Pat. No. 6,224,701, issued to D. A. Bryant, et al. on
May 1, 2001, and assigned to the assignee of the present invention,
discloses a molded plastic siding panel. This panel is molded with
the nail hem formed from two mating components connected by a
living hinge, and the locking tab projecting upward from the top of
the panel. After molding, the living hinge of the nail hem is
folded, and the two opposing components are secured to each other
initially by rivets on one half fitting with an openings on the
other half. The two halves are then thermally or ultrasonically
joined together. While this process has been found to produce a
siding panel of high quality and which is easy to install, a
simplified manufacturing process, having a reduced number of steps,
is desired.
SUMMARY OF THE INVENTION
[0010] The present invention provides a thermoplastic panel for
covering building surfaces that is simpler to produce than
conventional panels. The method of the present invention can be
used to produce panels for a variety of applications including
exterior walls, roofs, soffits and the like. In a preferred
embodiment, the panel includes a body with an attachment hem and
locking tab adjacent to the upper portion of the body, and a return
leg attached to the bottom of the body.
[0011] The panel is injection molded in a manner that permits it to
be withdrawn from the mold in a shape that is very close to the
final shape of the panel, with the attachment hem already
completely formed, and the locking tab close to its final position.
Pressure is applied to the locking tab as it cools, bringing it
closer to the panel, so that when it is fully solidified, it is
within its final, desired position.
[0012] The use of this injection molding method eliminates the need
to form a hinge within the nail hem, fold the nail hem, and then
attach the opposing portions of the nail hem together, after
injection molding the panel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a fragmentary front elevational view of a building
wall covered with plastic panels made in accordance with the
present invention.
[0014] FIG. 2 is a front elevational view of a plastic siding panel
according to the present invention.
[0015] FIG. 3 is a left side elevational view of a plastic siding
panel according to the present invention.
[0016] FIG. 4 is a right side elevational view of a plastic siding
panel according to the present invention.
[0017] FIG. 5 is a side elevational view of Detail 5 in FIG. 4.
[0018] FIG. 6 is a side elevational view of Detail 6 in FIG. 3.
[0019] FIG. 7 is a side elevational view of Detail 7 in FIG. 4.
[0020] Like reference characters denote like elements throughout
the drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] The present invention is directed toward an improved molded
plastic panel for covering building surfaces. While the following
description refers to an embodiment directed to a wall panel, the
invention is applicable to other building surfaces such as walls
roofs and soffits for example.
[0022] Referring to FIG. 1, an exterior wall 10 is covered by
several plastic panels 11. The panels 11 each include three
laterally extending, generally parallel rows of simulated wood
shingles 12, but the number of rows may vary. The shingles 12
preferably have irregular widths, and are separated from shingles
in the same row by vertically extending gaps 15 of varying widths.
The panels 11 may cover an entire exterior wall as shown in FIG. 1,
or they may be combined with other exterior wall coverings.
[0023] Referring to FIGS. 2-4, one of the panels 11 is shown in
greater detail. The panel 11 includes a body 16 divided into a
plurality of generally parallel, laterally extending rows, with
three rows 18, 20, 22 present in the illustrated example. The gaps
15 between the shingles 12 have widths that vary randomly within
predetermined limits in order to camouflage spacings between
adjacent panels accompanying thermal contraction and expansion.
[0024] Referring to FIGS. 3-5, an attachment hem 24 extends upward
from the top of the body 16. The attachment hem 24 includes an
attachment body 36 having a positioning rib 28 extending rearwardly
therefrom. A plurality of nail holes 30, surrounded by rearwardly
projecting reinforcing ribs 32, are defined within the attachment
hem 24. The positioning rib 28, and nail hole reinforcing ribs 32,
are dimensioned to permit the entire panel 11 to fit flat against
the side of a wall 10.
[0025] A locking tab 34 extends downward and slightly outward from
the attachment body 16, defining a channel 36 between itself and
the body 16. The locking tab 34 extends substantially across the
entire top of the panel 11. The locking tab 34 includes a tapered
nose 38 and the locking rib 40 projecting into the channel 36.
[0026] Referring to FIGS. 3 and 6, a locating ridge 42 projects
rearwardly from the intersection of the upper and middle rows 18
and 20, respectively.
[0027] Referring to FIGS. 4 and 7, the bottom of the body 16
includes a return leg 44 extending upward and rearward therefrom.
The return leg 44 defines a channel 46 between itself and the body
20. The return leg 44 includes a base portion 48 and a tip portion
50, with an obtusely angled corner 52 defined therebetween.
[0028] The panel 11 is preferably made from a thermoplastic polymer
selected from the group consisting of polyolefin, polycarbonate,
polyvinyl chloride, and mixtures and copolymers thereof
Polyolefins, especially polypropylene and mixtures and copolymers
with polyethylene, are particularly preferred.
[0029] The panel 11 is manufactured by injection molding. The mold
includes an elongated member structured to fit under that portion
of the plastic that will become the locking tab 34, and which takes
up the space of the channel 36. As the opposing molds portions are
withdrawn from a panel 11, the piece taking up the space of the
channel 36 will be moved downward with respect to the panel 11, out
of the channel 36, prior to or during removal of the mold portion
from the panel 11. At this point, the panel 36 is wider than
desired, but the plastic will still be warm and flexible. Downward
and inward pressure applied to the locking tab 34 will cause it to
cool and solidify in the desired position.
[0030] Referring to FIG. 2, the left side of the panel 11 includes
an outwardly extending fin 54, extending from the middle row 20.
Similarly, the right side of the panel 11 includes a pair of
outwardly extending fins 56, 58, extending from the upper row 18
and lower row 22, respectively. The fins 54, 56, 58 extend slightly
rearwardly, so that they will nestle underneath adjacent
panels.
[0031] To install the panels 11 on a wall 10, a starter strip is
first attached to the wall along its lower edge, in a manner well
known in the art of siding installation, as described in U.S. Pat.
No. 6,224,701, owned by the assignee of this invention, and
expressly incorporated herewith. The starter strips include a
downwardly opening groove structured to receive the return leg 44
of the lowermost row of panels 11. With the return leg 44 secured
within the starter strip, a panel is secured in place. The
engagement of the return leg 44 and starter strip is structured to
permit horizontal expansion and contraction of the panel. The upper
portion of each panel 11 is secured by driving fasteners through
the nail holes 30 and into the wall 10. The holes 30 are preferably
elongated to permit expansion and contraction of the panel 11
without buckling. Horizontally adjacent panels 11 are installed
with the flange 54 of one panel inserted between the adjacent
flanges 56, 58 of the adjacent panel, thereby resisting vertical
movement of one horizontally adjacent panel with respect to
another, while permitting horizontal movement due to thermal
expansion and contraction. The varying widths of the gaps 15 make
it more difficult to determine the locations of the joints between
adjacent panels, regardless of thermal expansion and
contraction.
[0032] Once the lowermost row of panels 11 is installed, the next
row of panels is installed by inserting the return legs 44
underneath the locking tabs 34, thereby securing the next row of
panels to the row of panels below it. Horizontally adjacent panels
are joined in the same manner as horizontally adjacent panels in
the previous row. Fasteners are again driven through the holes 30
within the attachment hem 24 to secure the upper edge of the panel
to the wall 10. The process continues until a desired portion of
the wall 10 is covered with panels 11.
[0033] The present invention therefore provides a molded panel
having a continuous locking tab along its top edge, extending
between the sides of the panel without any openings or spaces
therein. Such a continuous tab facilitates connecting the panel
with a vertically adjacent panel. The panel may be made by a
simplified manufacturing procedure, having fewer steps.
[0034] While specific embodiments of the invention has been
described in detail, it will be appreciated by those skilled in the
art that various modifications and alternatives to those details
could be developed in light of the overall teachings of the
disclosure. For example, panels produced in accordance with the
method of the present invention can be used as roofing panels and
in soffits. Accordingly, the particular arrangements disclosed are
meant to be illustrative only and not limiting as to the scope of
the invention which is to be given the full breadth of the appended
claims and any and all equivalents thereof.
* * * * *